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EP2064025B1 - Procédé de réparation - Google Patents

Procédé de réparation Download PDF

Info

Publication number
EP2064025B1
EP2064025B1 EP07817519.7A EP07817519A EP2064025B1 EP 2064025 B1 EP2064025 B1 EP 2064025B1 EP 07817519 A EP07817519 A EP 07817519A EP 2064025 B1 EP2064025 B1 EP 2064025B1
Authority
EP
European Patent Office
Prior art keywords
blade
repaired
rotor blade
metal powder
design data
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP07817519.7A
Other languages
German (de)
English (en)
Other versions
EP2064025A1 (fr
Inventor
Anja Lange
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MTU Aero Engines AG
Original Assignee
MTU Aero Engines AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by MTU Aero Engines AG filed Critical MTU Aero Engines AG
Publication of EP2064025A1 publication Critical patent/EP2064025A1/fr
Application granted granted Critical
Publication of EP2064025B1 publication Critical patent/EP2064025B1/fr
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00Restoring or reconditioning objects
    • B23P6/002Repairing turbine components, e.g. moving or stationary blades, rotors
    • B23P6/007Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20Direct sintering or melting
    • B22F10/28Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80Data acquisition or data processing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00Restoring or reconditioning objects
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/005Repairing methods or devices
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00Manufacture
    • F05D2230/80Repairing, retrofitting or upgrading methods
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49316Impeller making
    • Y10T29/49318Repairing or disassembling

Definitions

  • the invention relates to a repair method for blades of a gas turbine.
  • the rotor blades of gas turbines are subject to high mechanical and thermal stresses during operation, which can lead to cracking, as well as additional stresses due to wear.
  • the above stresses on the blades may necessitate repairing them after damage by renewing a damaged portion of the blade, particularly a blade tip thereof, from the blade and renewing it after removal.
  • a method of repairing a stator of a gas turbine in which a damaged portion is cut out of the nozzle to be repaired and a spare part for the cut-out portion is manufactured by means of a rapid manufacturing process.
  • the spare part produced by the rapid manufacturing process is integrated into the guide vane to be repaired by welding or soldering.
  • Another method for repairing gas turbine blades is from the DE 43 27 189 C2 It is known in which a damaged portion is separated from an airfoil of the gas turbine blade to be repaired and in which subsequently a repair plate is welded to the remaining airfoil stump of the gas turbine blade. Subsequently, the repair plate is processed on the desired airfoil profile.
  • a method of repairing a gas turbine blade comprising the steps of: a) providing a blade to be repaired; b) removing at least one damaged portion of a damaged blade tip from the blade to be repaired to form a separation surface; c) successively building up the or each removed portion or blade tip on the blade separation surface by a rapid manufacturing method using three-dimensional CAD design data of the blade, wherein as a rapid manufacturing method a two-stage process is used in which in each first step uniform powder bed is provided from a metal powder which is formed of the same alloy base material as the blade to be repaired and in a second step is selectively welded based on the three-dimensional CAD design data metal powder of the powder bed, repeated.
  • WO 2006/024844 A2 For example, a method of fitting a workpiece to geometric design data using a coordinate positioning apparatus is known. In the described method, a workpiece to be produced is measured between two production steps and the actual contour obtained is compared with the desired contour. A "fitting algorithm" calculates an adjustment of the workpiece with the axes of the production machine or an adjustment of the control commands for subsequent processing steps.
  • the present invention based on the problem to provide a novel repair method for blades of a gas turbine.
  • the present invention provides a gas turbine blade repairing method by which high quality repair is possible.
  • the repair method according to the invention is suitable for a multiplicity of damage cases on moving blades.
  • the repair method according to the invention makes do without expensive model and mold construction and thus permits relatively inexpensive repair of rotor blades, even on integrally bladed rotors such as blisks and blings.
  • the separation surface is measured, wherein if an actual contour of the separation surface determined thereby is more than a defined amount of a target contour determined by the CAD design data of the blade Separates separation surface, the CAD design data are adapted to the actual contour, whereby a transition profile between the actual contour and the target contour is determined.
  • the present invention relates to a method for repairing blades of a gas turbine.
  • Gas turbine blades may be so severely damaged during operation, eg due to oxidation, corrosion or erosion in the area of a blade tip, that the damaged blade tip must be replaced completely or partially.
  • the damaged blade to be repaired is first provided, and then the damaged blade tip or at least a damaged portion thereof is removed from the blade to be repaired to form a separation surface. It also means sections that extend from the blade tip to the entry or exit edge of the blade.
  • the position of the parting line or separating line for separating the section or the damaged blade tip from the blade of the blade is made dependent on the one hand by strength requirements, on the other hand, in the region of the separating surface, the blade must be free of coatings and radial cracks.
  • a two-step process is repeated.
  • a uniform powder bed of a metal powder is provided, wherein in a second step, the metal powder of the powder bed is selectively welded based on the three-dimensional CAD design data. Repetitive execution of this two-stage process, the new blade tip is built successively on the interface.
  • a metal powder is provided whose chemical composition is ideally of chemical composition corresponds to the blade to be repaired. At least, however, a metal powder is provided which is formed of the same alloy base material as the blade to be repaired. For example, if the blade to be repaired is made of a nickel-base alloy, a metal powder of a nickel-base alloy is used to provide the uniform powder bed.
  • a powder bed is provided with a maximum thickness of 200 microns, wherein the average grain size of the metal powder is preferably between 10 .mu.m and 150 .mu.m.
  • the uniform application of the powder bed can be done for example by means of a scraper.
  • metal powder is selectively welded onto the parting surface by means of laser beam welding or electron beam welding.
  • the blade freed from the damaged portion or the damaged blade tip is positioned in a process chamber of a rapid manufacturing plant for carrying out the rapid manufacturing process. If several blades are to be repaired simultaneously in a rapid manufacturing plant with the aid of the method according to the invention, then the separating surfaces of the different blades must be aligned exactly in one plane.
  • the process space of the rapid manufacturing plant is preferably filled with the metal powder up to the separating surface of the blade to be repaired.
  • the process space of the rapid manufacturing plant is either evacuated or filled with an inert protective gas during the welding of the powder on the parting surface of the blade to be repaired, oxidation is prevented.
  • the blades are preheated to weld the metal powder.
  • the new blade tip may be built with an excess of the outer contour of the blade to be repaired. In this case, reworking the new blade tip is mandatory.
  • the forming separating surface is measured and in this case an actual contour of the separating surface is determined.
  • a desired contour for the separating surface can be derived from the CAD design data.
  • the measured actual contour deviates from the calculated target contour by more than a defined amount
  • Contour of the separating surface is determined. This makes it possible to determine geometry differences between the actual contour and the desired contour of the parting surface, e.g. can be caused by wear or by production tolerances, compensate.
  • the welding parameters for welding the metal powder in the rapid manufacturing process are matched to the blade to be repaired as well as the material thereof and the metal powder.
  • the welding parameters both a polycrystalline and a monocrystalline and a directed he-stared building a new blade tip on the separation surface of the blade done.
  • a blade repaired by the repair method of the present invention may optionally be subsequently coated, e.g. in the region of a suction side and pressure side of the blade of the blade.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Laser Beam Processing (AREA)
  • Powder Metallurgy (AREA)

Claims (6)

  1. Procédé de réparation d'aubes de rotor d'une turbine à gaz, comprenant au moins les étapes suivantes dans l'ordre d'énumération :
    a) fourniture d'une aube de rotor à réparer ;
    b) extraction d'au moins une section endommagée d'une extrémité d'aube endommagé de l'aube de rotor à réparer, en formant une surface de séparation mesurée après l'extraction de la section ou de chaque section endommagée ou de l'extrémité d'aube endommagée de l'aube de rotor, les données CAO étant adaptées au contour réel si un contour réel de la surface de séparation ainsi déterminée dévie de plus qu'une mesure définie par rapport à un contour de consigne de la surface de séparation déterminé par les données CAO de l'aube de rotor, un profilé de transition étant déterminé entre le contour réel et le contour de consigne ;
    c) mise en place successive de la section ou de chaque section extraite ou de l'extrémité d'aube entière sur la surface de séparation de l'aube de rotor à l'aide d'un procédé de fabrication rapide utilisant des données CAO tridimensionnelles de l'aube de rotor, le procédé de fabrication rapide étant exécuté de manière répétitive comme un procédé en deux étapes selon lequel, dans chaque première étape, un lit de poudre uniforme constitué d'une poudre métallique est prévu, lequel lit de poudre est formé à partir du même matériau de base en alliage que l'aube de rotor à réparer et, dans une seconde étape, la poudre métallique du lit de poudre étant soudée de manière sélective sur la base des données CAO tridimensionnelles adaptées.
  2. Procédé de réparation selon la revendication 1, caractérisé en ce que, dans chaque première étape, un lit de poudre uniforme d'une épaisseur maximale de 200 µm est prévu.
  3. Procédé de réparation selon la revendication 1 ou 2, caractérisé en ce que, dans chaque première étape, un lit de poudre d'une granulométrie comprise entre 10 et 150 µm est prévu.
  4. Procédé de réparation selon au moins l'une des revendications 1 à 3, caractérisé en ce que, dans une étape sur deux, la poudre métallique est soudée de manière sélective par soudage par faisceau laser.
  5. Procédé de réparation selon au moins l'une des revendications 1 à 4, caractérisé en ce que, dans une étape sur deux, la poudre métallique est soudée de manière sélective par soudage par faisceau d'électrons.
  6. Procédé de réparation selon au moins l'une des revendications 1 à 5, caractérisé en ce que la section ou chaque section séparée ou l'extrémité d'aube entière est surdimensionnée sur la surface de séparation de l'aube de rotor, l'extrémité d'aube réparée étant ensuite retravaillée.
EP07817519.7A 2006-09-21 2007-09-13 Procédé de réparation Not-in-force EP2064025B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102006044555A DE102006044555A1 (de) 2006-09-21 2006-09-21 Reparaturverfahren
PCT/DE2007/001647 WO2008034413A1 (fr) 2006-09-21 2007-09-13 Procédé de réparation

Publications (2)

Publication Number Publication Date
EP2064025A1 EP2064025A1 (fr) 2009-06-03
EP2064025B1 true EP2064025B1 (fr) 2019-09-11

Family

ID=38896750

Family Applications (1)

Application Number Title Priority Date Filing Date
EP07817519.7A Not-in-force EP2064025B1 (fr) 2006-09-21 2007-09-13 Procédé de réparation

Country Status (4)

Country Link
US (1) US20090271985A1 (fr)
EP (1) EP2064025B1 (fr)
DE (1) DE102006044555A1 (fr)
WO (1) WO2008034413A1 (fr)

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Also Published As

Publication number Publication date
EP2064025A1 (fr) 2009-06-03
DE102006044555A1 (de) 2008-04-03
WO2008034413A1 (fr) 2008-03-27
US20090271985A1 (en) 2009-11-05

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